Continuous web perforating machine



Dec. 4, 1962 .1. A. EINHIPLE CONTINUOUS WEB PERFORATING MACHINE OriginalFiled April 12, 1955' 7 Sheets-Sheet 1 i-les ISI] Fig. I

INVENTOR.

John A. Einhiple ATTORNEY Dec. 4, 1962 .1. A. ElNHlPLE 3,066,542

CONTINUOUS WEB PERFORATING MACHINE Original Filed April 12, 1955 7Sheets-Sheet 2 Fig.2

INVENTOR. John A. Einhiple ATTORNEY 1962 .1. A. EINHIPLE 3,066,542!

CONTINUOUS WEB PERFORATING MACHINE Original Filed April 12, 1955 7Sheets-Sheet 3 Fig. 3

INVENTOR.

John A. Einhiple "Z; il/M ATTORNEY Dec. 4; 1962 J. A. EINHIPLE 3,066,542

CONTINUOUS WEB PERFORATING MACHINE Original Filed April 12, 1955 7Sheets-Sheet 4 mvsmox.

John A. Einhiple ATTORNEY Dec. 4, 1962 J. A. EINHIPLE 3,066,542

CONTINUOUS WEB PERFORATING MACHINE Original Filed April 12, 1955 7Sheets$heet 5 mm "mm 68 IHII!!! I 78 Fig.5

INVENTOR.

John A. Einhiple KMZ ATTORNEY Dec. 4, 1962 .1. A. EINHIPLE 3,066,542

CONTINUOUS WEB PERFORATING MACHINE Original Filed April 12, 1955 7Sheets-Sheet 6 80 so I I32 :30 I28 as so so I38 INVENTOR. Fig.6

John A. Einhiple ATTORNEY Dec. 4, 1962 l J. A. EINHIPLE 3,066,542

CONTINUOUS WEB PERFORATING MACHINE Original Filed April 12, 1955 7Sheets-Sheet 7 Fi 7 INVENTOR. John A. Einhiple ATTORNEY United StatesPatent Ofifice 3,066,542 Patented Dec. 4, 1962 3,066,542 CQNTHNUUUS WEBPERFQRATING MAQHZJE .lohn A. Einhiple, Kenmore, hLlL, assignor toNational Gypsum Company, Buffalo, NY, a corporation of Delaware Originalapplication Apr. 12, 1955, Ser. No. 500,?51, now Patent No. 2,855,998,dated (Pet. 14, N53. @ivided and this application July 17, 1958, Ser.No. 74%)?6 3 Claims. (U. 74-86) This invention relates to punchingperforations in a continuously advancing web and is particularlydirected to the perforating of gypsum board in the manufacture ofperforated gypsum lath.

This application is a division of my co-pending application Serial No.500,751, filed April 12, 1955, now US. Patent 2,855,998, issued October14, 1958.

Flat, rectangular boards comprising a set gypsum core and reinforcingpaper cover sheets, having a plurality of holes extending therethroughspaced evenly apart throughout the extent of the board, are a well knownform of lath, for application to building framework as a base materialfor subsequent application of the plaster wall surface. The perforatedform of board is well known as providing improved means for keying thesurface plaster to the lath.

The perforations are generally made in the gypsum board while the boardis still being advanced, as a continuous web, from the board formingmachine along a con veyor system on which the gypsum core becomespartially set. The perforating operation is performed near the end ofthis conveyor, immediately prior to the cutting of the web intoindividual boards for subsequent transfer to a drying kiln. The uncutboard, at the time of perforating, has set suificiently and attainedenough body to retain itself about a perforation Without flowing, but isstill considerably wet and weak, presenting difficulty in producing thedesired quality in the punched hole. The need of a punch, or punch anddie combination, capable of improving the quality or" perforations isrecognized.

The present most common method of forming these perforations is by amachine wherein a plurality of upper bolsters, each including aplurality of punches, cooperate with a plurality or" lower bolsters,each including a plurality of dies, the two sets of bolsters beingmounted on oppositely rotating spiders, the relation of all bolsterfaces to the horizontal being controlled by associated cams riding in acamway. The design of this prior machine recognizes the desirability ofmaintaining the punches and dies in a generally vertical dispositionthroughout an operative period of the cycle wherein the punches and diesare acting upon the moving web of board material, and it is for thisgeneral purpose that the cam and camway are incorporated into the priordesign. The bolsters make a complete rotation in each cycle,incorporating a whiptype action during the nonoperative portion of thecycle, necessitated by the vertically maintained condition during theoperative portion.

It has now been found, however, that this use of cams and camways inmaintaining verticularity during punching is highly subject to wear andloss of alignment, that close tolerances between punch and die cannot bemaintained without excessive parts replacement, and that a new andimproved punch structure, constructed in accordance with the presentinvention, cannot properly function in the absence of the closetolerances, within which the prior machines cannot be maintained for anyreasonable period of operation. The prior design, further, includes anexcessive number of power transmitting elements between upper and lowerspiders, each additional power transfer permitting additional sources oflost motion or misalignment due to inaccuracies or wear.

An object of the present invention is to provide, in a machine forperforating g psum lath or like material, means to maintain the closetolerances needed with the incorporation of the new punch which isclaimed in the above identified parent application; and to provide a newand improved motion for rotary punching; to provide a novel means forproviding the new motion.

These and other objects and advantages will appear more fully whenconsidered in connection with the following detailed description of apreferred embodiment of the invention and the accompanying drawings inwhich:

FIG. 1 is a front view of the right half of a rotary punching machineembodying the invention, parts having been broken away and parts shownin section as taken generally along line 1-1 of FIG. 2.

FIG. 2 is a right end view of the machine of PG. 1, cover plates havingbeen broken away.

REG. 3 is an enlarged view of the bolster support and drive elements ofFIG. 1, as taken along line 1-1 of FIG. 2.

FIG. 4 is a sectional view taken along the line 4-4 of FIG. 1.

PEG. 5 is an isometric view with parts broken away, of the structuraldetails of the bolster support and drive elements.

FIG. 6 is a sectional view taken along the line 6-6 of FIG. 1.

FIG. 7 is an enlarged sectional view of one pair of bolsters as shown inFIG. 6 showing the novel punches and cooperative dies.

General Description FIGS. 1 and 2 show the front and right end viewsrespectively of the lath perforating machine Ztl, through which acontinuous web of partially set, paper covered, gypsum board 22continuously passes. Although the machine 20 is capable of operating onboard passing from front to rear or reversely, it will be apparent thatwhen it is once installed for operation, usage will normally be in onedirection only.

Machine 20 is supported by a frame-base 24 having fixed thereon abed-plate 26 at each end thereof. Over each bed-plate 26 is an enclosedgear-box 28, made of a relatively light, removable, end cover-plate 3t);fixed, heavier-gauge, upper-shaft supporting, front-plate 32 andrear-plate 34; and a lower-shaft supporting main-plate 36.

Machine 20 includes a lower-shaft 38, rotatably supported in opposedlower-hubs 40 which are fixedly mounted in main-plates 36 at each end ofmachine 20. An upper-shaft 42 is rotatably supported in opposedupperhubs 44, which are the axially inner extent of hub supportingportions 45 of vertically-adjustably mounted upper-frames as, whichentire unit is slidably mounted for vertical movement of upper-shaft 42and its associated elements. By way of explanation, the punchingoperation of machine 20 is started and stopped by the lowering andraising of the upper-shaft 4-2 and its associated elements, while theshafts 33 and 42, and their associated elements, are rotatingsynchronously and the board 22 is passing therebetween. The completemechanism associated with this feature is discussed completely furtherbelow.

Fixed on the right end of lower-shaft 38, is a bevel-gear 48.Upper-shaft 42 has a similarly disposed bevel-gear 54, fixed at theright end thereof. With the exception of bevel gears 48 and 54 and theassociated conical gears and shaft disposed at the machine right end anda power input source at the right end, all discussed fully furtherbelow, the right and left ends of machine 20 are inverse counterpartsand, for this reason, disclosure will be directed, generally, to theright end, as shown in FIG. 1.

Inwardly of each end of lower-shaft 38, the shaft 38 is furthersupported, rotatably, in diagonal-braces 5i fixed to the bed-plates 26and front plates 32. inwardly from diagonal-braces 5t spur-gears 52 arekeyed to lowershaft 38.

Upper-frames 46 include axially outer cross members 55 which aredisposed axially inwardly of each end of upper-shaft 42. Cross members55 extend horizontally outward in each direction from shaft 42, as seenin FIG. 2, forming guide shaft bearing portions 57 which are slidablymounted on fixed vertically extending guide shafts 59. Cross members 55,by the fixed vertical relation with guide shafts 59, maintain upperframes 46 in true vertical positions.

Inward of cross-members 55 are spur-gears 56, disposed for meshing withspur-gears 52 when upper-shaft 42 is adjusted to its normal operating,lowest vertical position. The lower and upper hubs 4t and 44 aredisposed axially inward of the spur-gears 52 and 56, all of which hubsare fixed against rotation relative to the machine frame.

FIG. 5 is an isometric cutaway view of'the lower right hub 40 and itscooperative adjacent elements, the opposite lower hub portions and theupper hub portions being constructed similarly and shown with likenumerals designating similar parts.

Referring now to FIGS. 4 and 5, the horizontally eccentric relation ofshafts 38 and 42 relative to the axis of hubs 40 and 44 is seen.Lower-hubs 49 and upperhubs 44 each include an axially inwardlyprojecting, cylindrical inner-race 58, disposed about each of which is aroller-bearing 60. The races 58 and roller-bearings 60, will be seen inFIGS. 4 and 5 to be eccentrically disposed relative to the respectiveroller-shafts 38 and 42, which extend therethrough. Largeinside-diameter, hubsupported, cooperative spiders 62 are rotatablymounted on roller-bearings 60 and include six evenly circumferentiallyspaced end-sockets 64, all equally radially spaced from race 58.

Axially inward of lower-hubs 40 and upper-hubs 44 and fixedly, coaxiallymounted on the shafts 38 and 42, are small inside-diameter,shaft-mounted, supporting spiders 66, including six evenlycircumferentially spaced bearing-sockets 6%. Six crank-arms 70 arerotatably mounted between each pair of spiders 62 and 66, each crank-armcomprising an end-journal 72, rotatably disposed in an end-socket 64,-acrank-portion 74, and an inner bolster-journal 76, rotatably disposed ina bearing socket 68.

It will thus be seen that, with supporting-spiders 66, fixed to shafts38 and 4-2, rotation of these members will cause the crank-arms '70 andthe cooperative-spiders 62 to rotate evenly therewith and, due to thehorizontal eccentricity between the spiders 62 and 66, the crankarms 70will be held. horizontal throughout this rotation.

Referring now to the lower-shaft assembly, the inner bolster-journals 76of crank-arms '70, rotatably disposed in the axially inwardsupporting-spiders 66, are rigidly aifixed at their axially inner end 78to the ends of six lower die-supporting bolsters 80. Thus, sincedie-bolsters 80 are fixed relative to crank-arms 70, it will be apparentthat with rotation of spider 66 the die-bolsters 80 will be movedannularly about and completely around lowershaft 38 maintaining a fixedvertical position throughout this rotation.

Similarly on the upper-shaft assembly, the inner bolsterjournals 76 ofcrank-arms 70 are rigidly afiixed at the axially inner ends 82 to theends of six upper punchsupporting bolsters 84. Punch-bolsters $4 rotateabout upper-shaft 42, in fixed vertical position oppositely andsynchronously to the rotation of the die-bolsters 80.

It should be definitely noted that in FIG. 1 the two spiders 62 and 66,which are eccentric one to the other, are both cross sectioned throughtheir respective centers, which are not in the same plane, in order tomore clearly disclose the relation between the elements and the trans-4. mission of motion throughout the elements of machine 29. For theclearest understanding of the relation of the bolster support and driveelements, attention is directed to FIGS. 4 and 5, PEG. 3 being takenalong a broken plane, see line 1-1 of FIG. 2.

Referring back to FIG. 1, guide pins 85 are shown extending downwardlyone being disposed in each end of punch bolsters 34- and complementaryguide holes 87 are disposed in each end of die bolsters 86 for receptionof guide pins 85 to further maintain the close tolerance cooperationbetween opposed bolsters.

Referring now to FIG. '7, a cooperative pair of bolsters are shown inoperating position, including a die bolster 80, at its uppermostposition in its cycle of rotation, and a punch bolster 84-, at itslowermost position in its cycle of rotation. Punch bolster 34 includesan inverted T-shaped body portion 8 which is reinforced at spacedpositions along its extent with webs 88. Two rows of cylindricalperforating punches 90 are mounted to extend downwardly from the bottomfaces of punch bolsters 84, the punches 90 being alternately staggeredin pairs, to provide improvgd spacing of perforations in the finishedperforated boar The punches 96 are solid cylindrical bodies having adepression 92 for lockingly engaging the punch 9G with a set screw 94-.The cutting end faces 86 are concavely formed, substantially as thoughsevered semi-cylindrically, that is by a plane which is arcuate in onedirection. The faces 396 have a leading cutting edge 98 projectingaxially further than an opposite, trailing cutting edge 100. Thedifference in projecting distance is the result of spacing the axis ofthe abovesaid arcuate plane from the punch axis, avoiding anintersecting of axes. It will be seen that the difference in projectingdifference will be dependent upon the spacing of axes and the arcualradius. The preferred axial difference in length of edge 98 and edge 1%is substantially equal to the thickness of board 22. The punches aredisposed in bolsters 8 with leading edges 98 disposed away from theadjacent punch in the opposite row, so that equal and opposite thrustsare created by adjacent punches.

Die-bolster 80 includes an upright T-shaped body portion 102, which alsois reinforced at spaced positions along its extent with webs 104. Tworows of hollow cylindrical dies 106 are mounted on the top face ofdie-bolster 80, alternately staggered in pairs for reception of thepunches 9d. The dies 106 are formed with a depression 108 for engagementof set screws 110 for locking the die relative to bolster 80. Dies 106are disposed in holes 112 which extend entirely through the bolsterflange portions 114, the arrangement being that board material, in theform of slugs, which is removed by the punches and dies, will passentirely through the flange portion 114. These slugs are caught inretaining chambers 116, which are formed beneath each row of dies oneach side of the bolster by elongate doors 118, each door extendingthroughout the undersurface of one side of each bolster 80. Doors 118are so mounted, as will be described herebelow, that they are caused toopen when the die bolsters 89 are located at the lowest point in thecycle preventing slugs of waste material from falling from a bolster inoperating position at the top of the cycle onto the top face of abolster located therebelow.

Each punch bolster 84 further includes a spring loaded stripper plate120, which is disposed below and extends throughout the extent of thebottom face of the punch bolsters. Springs 122 continuously urge thestripper plate downward, and spring core bolts 124, disposed through thecenter of spring 122, slidably mounted, in a fixed vertical position, inthe flange portions 114 of bolsters 84, preferably at a web 83, andfixed at the end thereof in stripper plate 120, maintain the aligmnentof stripper plate 129. It will be apparent that as the upper bolster inFIG. 7 moves upward, stripper 129 prevents web 22 from moving upwardtherewith, see F IG. 6, as might otherwise occur due to friction onpunches 90.

By referring to FIGS. 6 and 7, the operation of the slug catching doors118, will be more clearly apparent. Doors 118 are pivotaly mounted onrotatably mounted, pivot-shafts 128, extending throughout the length ofthe respective doors. Pivot-shafts 128, at each end of doors 118, areconnected through linkages 130 and 132, which are further connected toannular rings 134. Rings 134 are rotatably mounted at each end ofdie-bolster 80, and have extending therefrom camway follower rollers136, rotatably disposed therebelow. A camway 138, mounted on frame 24,is located along the lower periphery of the path of rollers 136 duringrotation of bolsters 80. Camway 138 causes rollers 136 to move sidewardsrelative to the bolsters 80, rotating the annular rings 134, which,through linkages 130 and 132, operate pivot-shafts 128, opening doors118. Further progression of roller 136 along camway 138 allows roller136, due to the shape of camway 138, to return to its normal centralposition, reclosing, by means of the same mechanisms, the doors 118.

Referring now to FIG. 1 and FIG. 2, a power source (not shown), in anyusual form, drives by means of a drive shaft 140, a gear 142 which isconstantly in mesh with lower spur gear 52.

When the upper shaft 42 and its associated punch bolsters 84 areadjusted to their normal operating, lowest vertical position, a directdrive from lower to upper shaft is maintained at each end of the machinethrough the cooperative spur gears 52 and 56. During a change from anoperating to a nonoperating condition, which is accomplished by raisingthe upper shaft 42 and punch bolsters 84, a continuous condition ofsynchronism must be maintained between the punches 90 and dies 106. Thissynchronism is provided by means of a vertical shaft 144- at the rightend of machine 20', and is included in FIG. 1 for clear disclosurealthough it is disposed in front of the sectioning plane 11 as will beseen in FIG. 2. Shaft 144 has a lower conical gear 146 fixed thereon tocooperate with lower bevel gear 48. Conical gear 146 is driven by bevelgear 48 and drives vertical shaft 144, on which is axially-slidablykeyed an upper conical gear 148 for intermeshing with and driving upperbevel gear 54. Vertical shaft 144 is rotatably and slidably supported atits upper portion by a hollow cylindrical mounting 149 affixed to anupper outer face plate portion 151 of upper frame 46.

The raising and lowering of the upper shaft 42, and punch-bolsters 84,is accomplished by means of a raising and lowering mechanism, actingthrough each end of machine 20, the right end of which is showngenerally in FIG. 1. Reference may be made to my US. Patent 2,957,369for a full description of the preferred form of the raising and loweringmechanism.

As will be readily seen from FIG. 1, the raising and lowering mechanismsare contained and supported in an enclosed overhead housing 166,extending between and supported on the two gear boxes 28. A lubricantreservoir 168 with sight glasses 170 at each end thereof is alsodisposed in housing 166. An oil pump 172, seen in FIG. 2, is driven bydrive shaft 140', through chain 173, the balance of the lubricatingsystem not being shown.

Having completed a detailed disclosure of a preferred embodiment of myinvention so that those skilled in the art may practice the same, Icontemplate that variations may be made without departing from theessence of the invention or the scope of the appended claims.

I claim:

1. In a machine of the class described having a plurality of bolstersmounted for movement in a circular path about a central axis whileremaining throughout said movement in constant parallelism, whereby anygiven surface of any of said bolsters is always disposed in a planewhich is parallel to the plane in which it was disposed at any otherposition in its said movement in a circular path, said machinecomprising a frame having mounted thereon stationary cylindrical hubshaving an axis parallel and spaced from said central axis, a shaftrotatably mounted in each said hub coaxial with said central axis havinga supporting spider coaxially mounted thereon, an annular cooperativespider having an annular inner periphery rotatably mounted substantiallythroughout said periphery coaxially upon each said hub whereby saidsupporting spiders are positively, eccentrically disposed relative tosaid cooperative spiders with a plurality of small rollable bearingsdisposed between said cooperative spider and said hub, a plurality ofaxially extending, equi-radially disposed sockets in each of saidsupporting spiders and said cooperative spiders, a plurality ofcrank-arms each rotatably mounted in a socke of one of said supportingspiders and a socket of an adjacent cooperative spider, said pluralityof bolsters being rigidly fixed to the ends of said crank-arms, whichsaid ends are disposed in a socket of said supporting spiders, and meansfor rotating said shaft and said spiders.

2. In a machine of the class described having an upper and a lower setof bolsters mounted for synchronized opposed rotary movement, with saidbolsters each remaining throughout said movement in constantparallelism, whereby any given surface of any of said bolsters is alwaysdisposed in a plane which is parallel to the plane in which it wasdisposed at any other position in its said movement in a circular path,said machine comprising a frame having mounted thereon upper and loweraxially parallel stationary cylindrical hubs, an upper shaft and a lowershaft each rotatably mounted eccentrically in said respective hubs,means for rotating said respective shafts equally and oppositely, asupporting spider c0 axially mounted on each said shaft closely adjacentand spaced from each end thereof, an annular cooperative spider havingan annular inner periphery rotatably and coaxially mounted substantiallythroughout said periphcry on each said hub adjacent to at least one ofthe supporting spiders on each shaft and eccentric to said supportingspiders with a plurality of small rollable bearings disposed betweensaid cooperative spider and said hub, a plurality of axially extending,equi-radially disposed sockets in each of said supporting spiders andsaid cooperative spiders, a plurality of crank-arms each rotatablymounted in a socket of one of said supporting spiders and a socket of anadjacent cooperative spider, and one of said bolsters rigidly fixed toan end of each said crank-arm, which said end is disposed in one of saidsuporting spider sockets.

3. In a machine of the class described, a frame, an upper shaft and alower shaft each mounted rotatably relative to said frame, means forrotating said shafts equally and oppositely, supporting spiderscoaxially mounted on each said shaft closely adjacent and spaced fromeach end thereof, stationary cylindrical hubs mounted on said frameeccentrically supporting said shafts adjacent said supporting spiders,annular cooperative spiders each having an annular inner peripheryrotatably, coaxially mounted throughout said periphery substantiallydirectly upon each said hub adjacent and eccentric to said supportingspiders with a plurality of small rollable bearings disposed betweensaid cooperative spider and said hub, a plurality of axially extending,equiradially disposed sockets in each of said spiders, a plurality ofcrank-arms each rotatably mounted in a socket of said supporting spidersand a socket of an adjacent cooperative spider, and a plurality ofbolsters each rigidly fixed to and suported by a respective end of saidcrankarms, which said end is disposed in one of said supporting spidersockets.

(References on following page) References Cited in the file of thispatent UNITED STATES PATENTS Howard Sept. 15, 1857 True Oct. 6, 1885Heebner July 20, 1896 Nichols May 23, 1899 Rhodes Jan. 11, 1910Buschmeyer Mar. 16, 1920 Parcher Ian. 11, 192 7 Bu'nr Dec. 25, 1928Schillo July 27, 1937 Haegele Feb. 10, 1942 8 Browne Nov. 14, 1950Eberhardt Nov. 21, 1950 Skillman July 24, 1951 Rosenleaf June 2, 1953Gregory Jan. 26, 1954 FOREIGN PATENTS Sweden Sept. 16, 1920 OTHERREFERENCES divided.

